Protector for electrical terminals

ABSTRACT

The protector has a pocket of insulating material which encloses the spliced stripped ends forming the terminal of electrical conductors, the terminal being secured in the pocket to prevent removal therefrom. In addition, a cord strain relief on the protector secures the conductors to the protector independently of the pocket to provide another lock which prevents removal of the terminal from its pocket, to thereby effect two safety features against possible exposure of the terminal causing shock hazards when embodied in an electrical appliance.

United States Patent Inventor Jerry L. Balzer 7574 Carmen Drive N.W.,North Canton,

Ohio 44720 Jan. 19, 1970 Nov. 2, 1971 Appl. No. Filed Patented PROTECTORFOR ELECTRICAL TERMINALS [56] References Cited UNITED STATES PATENTS1,176,288 3/1916 Hamilton 174/87 3,139,481 6/1964 Swanson 174/1384Primary Examiner-Darrell L. Clay Attorneys-Alfred G. Gross and Elmer A.Johnson ABSTRACT: The protector has a pocket of insulating materialwhich encloses the spliced stripped ends forming the terminal ofelectrical conductors, the terminal being secured in the pocket toprevent removal therefrom. In addition, a cord strain relief on theprotector secures the conductors to the protector independently of thepocket to provide another lock which prevents removal of the terminalfrom its pocket, to thereby effect two safety features against possibleexposure of the terminal causing shock hazards when embodied in anelectrical appliance.

1 PROTECTOR FOR ELECTRICAL TERMINALS BACKGROUND OF THE INVENTION Theinvention relates to protectors for spliced ends forming terminals ofconductors adapted to be included in the circuit of an electricalappliance. The protectors completely enclose the bare ends of theterminals and provide a plurality of locking means to prevent removalfrom the protectors in the event the terminals have been improperlyspliced or inserted in the protectors to thereby avoid shock hazards.

SUMMARY According to the present invention the terminal protector ismade from electric insulating material and includes a pocket which maybe an integral part of or separate from the body of the protector. Thebare terminal is inserted in the pocket and the latter is provided witha lock to prevent removal of the terminal and the wires forming theterminal. The pocket can also be provided with a metal connector whichis squeezed about the terminal to improve the electrical connectionbetween the spliced conductors, or the metal connector can be omittedand threads molded into the pocket and the stripped ends of theconductors threaded into the pocket to form a spliced terminal.

In addition, the protector is provided with a cord strain relief whichlocks the insulated portions of the conductors to prevent movement ofthe latter relative to the terminal in the pocket and to the protector.

Thus, it is an object of the invention to provide a terminal protectorhaving two locking devices, both of which operate to retain the terminaland the bare wires forming the latter within the pocket of theprotector.

DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of the firstembodiment of the invention showing the protector in open position,

FIG. 2 is a perspective view of the protector but shown in closed lockedposition,

FIG. 3 is a section along line 3-3 in FIG. 2,

FIG. 4 is a section along line 4-4 in FIG. 2,

FIG. 5 is a broken view of an electrical appliance, such as a suctioncleaner, showing the protector embodied in the circuit of the appliance,

FIG. 6 is a section along line 6-6 in FIG. 7 ofa second em bodiment ofthe invention showing the pocket as an integral part of the protector,

FIG. 7 is a section along line 7-7 in FIG. 6,

FIG. 8 is a section of the metal connector separated from the protectorin FIG. 6,

FIG. 9 is a section along the line 9-9 in FIG. 10 disclosing a thirdembodiment of the invention wherein the metal connector is press-fittedinto the pocket,

FIG. 10 is a section along line 10-10 in FIG. 9,

FIG. 11 is a section of the metal connector separated from the protectorin FIG. 9,

FIG 12 discloses a fourth embodiment of the invention wherein threadsare molded into the pocket, and is taken along the line 12-12 in FIG.13, and

FIG. 13 is a section along line 13-13 in FIG. 12.

DESCRIPTION OF THE FIRST EMBODIMENT The embodiment of the invention inFIGS. 1 to 4 discloses a protector 15 for an electric terminal andcomprises a body 16 of Polypropylene, Nylon, Delrin or other suitablemoldable electric insulating material, having opposite end portions 17and 18 connected by a relatively flexible intermediate portion 19.Midway in the portion 19 is an opening 20 in which is supported a pocket21 forming an enclosure for an electric terminal 22. The electricterminal 22 includes twisted-together bare ends 23 and 24 of electricalconductors 25 and 26 respectively. each of which are coated withinsulation 27.

The pocket 21 is of tubular configuration formed of molded electricinsulating material closed at one end 28 and its opposite end isprovided with an opening 29 for insertion of the terminal 22. The pocket21 includes a reduced tubular section 30 extending from the closed end28 to a shoulder 31 from which extends an enlarged tubular skirt section32 terminating at the inlet opening 29.

A metal sleeve or connector 34 is secured in the reduced tubular section30 during the molding of the pocket 21 and receives the twisted ends ofthe terminal 22 when the latter has been inserted through the opening 29of the pocket 21. The connector or metal sleeve 34 and the enclosingreduced tubular section 30 are suitably crimped as indicated at 35, tomore firmly secure the terminal 22 in the sleeve 34 and the latter tothe reduced tubular section 30, and to also clamp the stripped ends23-24 of the conductors 25-26 together to form a good electricalconnection therebetween. Thereafter, the pocket 21 is supported on theintermediate portion 19 of the protector 15 by inserting the tubularsection 30 through the opening 20 until the shoulder 31 abuts the innersurface 36 of the body intermediate portion 19, and the insulation 27 ofthe conductors 25-26 overlie the end 17 of the protector body 16, asshown in FIG. 1.

The opposite ends 17-18 of the body 16 are formed complementary to eachother to provide a cord strain relief 38 having an undulatinglongitudinally extending passageway 39 when the protector is in itsfolded position to accommodate the electrical conductors 25 and 26 asshown in FIG. 4. The end 17 of the body 16 has a rib 40 disposed betweentwo concaved surfaces 41 which extend transversely of the body and abutthe side wall 42 of two latch keepers 43 to define an undulating surfacehaving the rib 40 terminating short of the top surface 44 of the latchkeepers 43. The other complementary end 18 of the body 16 is providedwith a rib 45 recessed with respect to two spaced convexed projections46.

It will be noted from FIG. 4 that when the body 16 is in its foldedposition the convex projections 46 are arranged opposite theircooperating concaved surfaces 41 and the ribs 40-45 bend the electriccords 25-26 in the passageway 39 to prevent displacement of the cordsrelative to the protector 15 and the terminal 22 with respect to thepocket 21.

In order to lock the protector 15 in its folded position, each of thekeepers 43 in the body end portion 17 is provided with an opening 47which extends through the body 16, and the outer wall 48 of each keeper43 is shorter than the opposite inner wall 49 to form a shoulder 50. Atthe other end 18 of the body 16, along its opposite edges, is aprojecting tongue 51, each provided with a latch flange 52 adapted to beinserted into its opening 47 for engagement with the shoulders 50 in thebody other end portion 17 to lock the protector 15 in its latched foldedposition, whereby the electric cords 25-26 will be retained againstdisplacement in the passageway 39 when a pull is applied to theconductors in the direction of the arrow 53 shown in FIG. 4, to preventthe pull being transferred to the spliced terminal 22, the connector 34and reduced tubular pocket portion 30. The latching tongues 51 arebiased outwardly from the inner sidewalls 49 of the openings 47 so thatthe flanges 52 move into engagement with the shoulders 50 when the bodyis folded about the pocket to lock the protector 15 in its foldedposition.

It will be noted in FIG. 3 that the latching tongues 51 have their innersurfaces spaced from the adjacent inner wall 49 of the openings 47 asindicated at 54. These spaces 54 permit the latching tongues 51 to bepressed inwardly against the inner walls 49 of the openings 47 so thatthe flanges 52 clear the shoulders 50, whereby the tongues 51 can bewithdrawn from the keepers 43 allowing the body ends 17 and 18 to beseparated from each other to expose the electric cords 25 and 26 asshown in FIG. 1.

When the body 16 is unfolded, the pocket 21 can be removed from theprotector 15 and a different pocket and terminal inserted in the opening20 and thereafter the body is again folded to its locked condition.

The terminal 22 is attached to the protector by inserting it in themetal connector 34 in the pocket 21, and thereafter suitable crimpingtool is applied to the reduced portion 30 of the pocket 21 to lock theterminal 22 with respect to the metal connector 34 and pocket 21, asindicated by the opposed crimped areas 35. The pocket 21 is theninserted through the opening in the protector 15 with the cords -26arranged over the rib as shown in FIG. 1. The protector 15 is thenfolded about the tubular portion 32 of the pocket 21 into its lockedposition by inserting the tongues 51 into the keeper openings 47 untilthe flanges 52 engage the shoulders 50. When the protector 15 is in itsclosed folded position the cords 25-26 are bent in the passageway 39 andthe opposing ribs 40-45 press into the insulation of the cords tosecurely lock them relative to the body to further insure that a strainwill not be placed upon the spliced wires of the terminal 22 and alsothe pocket 21 cannot be removed from the protector 15 to expose thestripped ends 23-24 of the conductors and cause a possible shock hazard.

The open end 29 of the pocket 21 is spaced a short distance from theinner surfaces 56 of the body end portions 17-18 so that if the pocket21 is displaced in its opening 20, the pocket end 29 will abut thesurfaces 56 to prevent the reduced end 30 of the pocket from beingdislodged through the opening 20.

The protector 15 is particularly adapted for use in electricalappliances, for example a canister-type suction cleaner 57, as shown inFIG. 5. The cleaner 57 includes a body 58 having a base 59 provided witha cover 60 for access to the interior of the cleaner body. A motor 61 ismounted in the body 58 and is connected in an electric circuit,including one of the power leads 62, a wire 63 from the motor 61 to theprotector 15, from which extends conductor 64 to a switch 65 connectedto the other power lead 66.

In the event the cord strain relief structure has not been lockedproperly so that the protector l5 unfolds, as for example as shown inFIG. 1, the bare ends of the terminal 22 remain covered by the pocket21, or if the terminal 22 is improperly made or assembled in the pocket21, the bare wires forming the terminal 22 will not be exposed becauseof the locked cord strain relief structure 38, and accordingly, theterminal 22, and the bare ends 23-24 of the cords 25-26 respectively cannot contact a metallic part of the cleaner and create a shock hazard.

DESCRIPTION OF THE SECOND EMBODIMENT A second embodiment of theinvention is disclosed in FIGS. 6 to 8 and comprises a protector moldedfrom suitable plastic material.

In the present embodiment the protector 70 includes a body 71 havingopposite end portions 72 and 73 connected by a flexible intermediateportion 74. Midway in the body intermediate portion 74 and projectingfrom opposite sides 75 and 76 thereof is an integrally molded pocket 77having a reduced section 69 provided with a closed end 78 projectingbeyond the outer face 75 of the body intermediate portion 74, and askirt 79 extends from the other face 76 and terminates in an inletopening 80.

Projecting from the pocket opening80 are two diametrically arrangedlatch fingers 81 provided at their free ends with a shoulder 82, and thelatch fingers 81 are normally biased toward the interior of the pocketopening 80 A tubular metal connector or sleeve 83 is seated in thepocket 77 and includes a reduced portion 84, an inclined section 85 anda skirt portion 86 having an outwardly radially flared edge 87 at theentrance 88 to the connector 83.

The terminal 90 formed by the spliced bare ends 91-92 of the electricalconductors 93-94 respectively are secured within the reduced portion 84of the connector 83 by use of a crimping tool which forms theindentations 95 in the reduced portion 84 ofthe connector 83.

The connector 83 and terminal 90 are removably secured in the pocket 77by inserting the connector into the reduced portion 69 of the pocket 77to such an extent that the shoulder 82 of each latch finger 81 engagesthe flared end 87 of the connector 83, as shown in FIG. 6.

The thickness of the intermediate portion 74 of the body 71 at oppositesides of the pocket 77 is reduced as indicated at 96 to provide a pairof hinges so that intermediate portion 74 may be folded into lockedposition over the latch fingers 81 as shown in FIG. 6 to prevent accessthereto when the protector is in its folded locked position.

The opposite end portions 72-73 of the body is provided with the cordstrain relief 38 described in connection with the first embodiment ofthe invention in FIGS. 1 to 4, and accordingly the cords 93-94 arelocked to the protector 70 to prevent any stress being applied to theterminal 90, connector 83, or the pocket 77.

From the foregoing it will be apparent that the terminal 90 is locked inthe connector 83 by the crimped metal indentations 95 and the connector83 is locked in the pocket 77 by the latch fingers 81, however, if it isdesired to replace the connector 83, the latch fingers 81 may be spreadapart from the flared end 87 of the connector 83 to release the latterfrom the pocket 77.

This embodiment, as in the first, provides a double lock to preventremoval of the terminal 90 from the pocket 77, because the latch fingers81 form one locking device and the cord strain relief 38 an additionallatch for the conductors 93-94 and thus for the terminal 90 andconnector 83.

DESCRIPTION OF THE THIRD EMBODIMENT Another embodiment of the inventionis disclosed in FIGS. 9 to 11 and comprises a protector 97 molded fromsuitable plastic material and is provided with a body 98 having oppositeend portions 99-100 connected by a flexible intermediate portion 101 inwhich is molded a pocket 102 projecting from the opposite sides 103-104thereof. The pocket 102 is tubular and has a closed end 105 in a reducedportion 106 and is provided with an annular recess 107 from whichextends a skirt section 108 having an opening 109.

A tubular metal sleeve or connector 111 is disposed in the reducedportion 106 of the pocket 102 and includes a cylindrical section 112terminating in an opening 113 having a flanged end 114. The externaldiameters of the cylindrical section 112 and the flanged end 114 are sosized with respect to the interior diameters of the pocket reducedsection 106 and annular recess 107, that the connector 111 is secured inthe pocket 102 by forcing it into the pocket to form a press-fittherewith.

The remainder of the protector 97 is similar to that described in FIGS.6 to 8 and includes a pair of hinges 96 and the cord strain relief 38 tosecure the conductors 115-116 to the protector 97.

In this embodiment the bare ends 117-118 of the conductors 115-116 arespliced together to form a terminal 119 which is inserted in theconnector 111 and the latter is crimped to the terminal 119 as indicatedat 120 by a crimping tool. The connector 111 is press-fitted into thereduced area 106 of the pocket 102 to prevent removal from the latterand thus provides one lock to prevent removal of the terminal 119. Inaddition, the cord strain relief 38 locks the conductors 115-116 andthus prevents a stress being applied therethrough to the terminal 119 inthe pocket 102.

DESCRIPTION OF THE FOURTH EMBODIMENT The final embodiment of theinvention is shown in FIGS. 12 and 13 and comprises a protector 121molded from suitable plastic material and is provided with a body 122having opposite end portions 123-124 and an intermediate portion 125 inwhich is molded a pocket 126 projecting from the opposite faces 127-128of the body intermediate portion 125. The portion 129 of the pocket 126projecting from the face 127 has a closed end 130 and a conical-shapedinterior provided with molded threads 132 which terminate in an enlargedskirt portion 133 having an opening 134.

The remainder of the protector 121 is similar to that described in FIGS.9 to 11 and includes a pair of hinges 96, and the cord strain relief 38to secure conductors 135-136 to the protector 121.

In order to assemble the cords 135-136 in the protector 121 the latteris opened to a position similarto that shown in FIG. 1 and the unsplicedbare ends 137-138 of the cords are inserted through the opening 134 intothe pocket 126. The cords 135-136 are then rotated in a clockwisedirection to thread the bare ends 137-138 inwardly into theconicalthreaded portion 132 of the pocket 126. Continued rotation of thebare ends 137-138 cause the latter to advance toward the closed end 130of the pocket 126 to confine the ends in a smaller area as the diameterof the conical tube decreases. Such rotation and the reduction of spacetoward the closed end 130 of the conical portion 132 causes the barewire ends 137-138 to become twisted together, that is spliced, to form aterminal 139. In addition, the terminal 139 is retained in the conicaltubular portion 132 by being embedded in the threads to thereby preventremoval of the terminal 139 from the pocket 126.

The cord strain relief 38 provides another look to secure the conductors135-136 relative to the protector 121 and the pocket 126 to therebyassure that the terminal 139 will not be dislodged from the pocket 126and cause a shock hazard.

It will be understood that the disclosed structure is for illustrativepurposes only and is not to be taken in a limiting sense. The presentinvention includes all equivalent variations of the disclosed structureand is limited only by the scope of the claims.

lclaim:

l. A protector for the stripped terminal ends of insulated electricalconductors, comprising:

a body of flexible dielectric material having means providing a pocketfor receiving the stripped ends of two electrical conductors;

locking means in said pocket for retaining said conductor stripped endstherein;

strain relief means carried by said body in spaced relation to saidpocket for locking said conductors to said body independently of saidpocket locking means; and

said strain relief means including upper and lower portions securabletogether and such portions having respective surfaces in facing relationcooperable to provide an undulating passageway for said conductors.

2. A protector for the stripped terminal ends of insulated electricalconductors as described in claim 1, wherein:

said body is elongated;

said upper and lower strain relief portions are located at opposite endsof said elongated body; and

said means providing a pocket being disposed intermediate said upper andlower strain relief portions.

3. A protector for the stripped terminal ends of insulated electricalconductors as described in claim 1, wherein:

said means providing a pocket in said body extends in a directiontransverse to the longitudinal axis of body; and

said means for providing a pocket in said body further provides anentrance to said pocket which entrance faces said strain relief meanswhen said upper and lower portions are secured together.

4. A protector for the stripped terminal ends of insulated electricalconductors as described in claim 1, including:

a metal connector disposed in said pocket for receiving said strippedterminal ends; and

said locking means in said pocket engages said metal connector forreleasably locking said metal connector in said pocket.

5. A terminal protector as described in claim 4, wherein:

said locking means in said pocket includes a latch finger formed of aresilient material to releasably engage said metal connector; and

said latch finger engages the end of said metal connector locatedadjacent said strain relief means. 6. A protector for the strippedterminal ends of insulated electrical conductors as described in claim1, including:

a metal connector disposed in said pocket for enclosing said terminaland the external diameter of said metal connector is smaller than theinternal diameter of said pocket to cause an interference fit when saidmetal connector is placed inside of said pocket.

7. A protector for the stripped terminal ends ofinsulated electricalconductors as described in claim 1, wherein:

said elongated flexible body being generally in the shape of a flatstrip;

said pocket being supported on an intermediate portion of said bodystrip;

said body strip being foldable about said pocket; and

said upper and lower strain relief portions, located on said body stripend portions, being securable together for locking said conductors insaid undulating passageway and retaining said body strip intermediateportion folded about said pocket.

8. A protector for the stripped terminal ends of insulated electricalconductors as described in claim 1, wherein said means providing apocket being removably supported in an opening in said body;

said means providing a pocket having an enlarged portion at one endthereof to prevent said pocket providing means from pulling through oneside of said body opening: and

said strain relief means, when locked about said conductors, beingarranged with respect to said pocket providing means to abut saidenlarged portion to prevent removal of said means providing a pocketfrom the second side of body opening.

9. A protector for the stripped ends forming the terminal of electricalconductors, comprising:

a. a body of flexible insulating material;

b. a pocket supported on said body for enclosing the stripped ends ofconductors forming a terminal;

c. locking means in said pocket for locking said terminal and saidconductors in said pocket;

d. cord strain relief means on said body beyond one end of said pocketfor locking said conductors to said body independently of said lockingmeans for said terminal and conductors; and

e. said body formed of molded plastic material with said pocket formingan integral part thereof, and thread means molded in the interior ofsaid pocket for receiving said stripped ends of said conductors,rotation of said stripped ends along said molded thread means splicingsaid ends together and securing the latter in said pocket.

I t i t UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent N Dt d November 2,

Inventor) Jerry L Balzer It is certified that error appears in theabove-identified patent and that said Letters Patent are herebycorrected as shown below:

On the cover sheet insert [73] Assignee The Hoover Company, NorthCanton, Ohio Signed and sealed this 24th day of October 1972.

(SEAL) Attest:

EDWARD M.FLETCHER,JR. ROBERT GOTTSCI'IALK Attesting Officer Commissionerof Patents RM PO-10 (10-69) USCOMM-DC 50:41am

UVS GOVERNMENT PRENTING OFFICE: 9.9 0-366-534

1. A protector for the stripped terminal ends of insulated electricalconductors, comprising: a body of flexible dielectric material havingmeans providing a pocket for receiving the stripped ends of twoelectrical conductors; locking means in said pocket for retaining saidconductor stripped ends therein; strain relief means carried by saidbody in spaced relation to said pocket for locking said conductors tosaid body independently of said pocket locking means; and said strainrelief means including upper and lower portions securable together andsuch portions having respective surfaces in facing relation cooperableto provide an undulating passageway for said conductors.
 2. A protectorfor the stripped terminal ends of insulated electrical conductors asdescribed in claim 1, wherein: said body is elongated; said upper andlower strain relief portions are located at opposite ends of saidelongated body; and said means providing a pocket being disposedintermediate said upper and lower strain relief portions.
 3. A protectorfor the stripped terminal ends of insulated electrical conductors asdescribed in claim 1, wherein: said means providing a pocket in saidbody extends in a direction transverse to the longitudinal axis of body;and said means for providing a pocket in said body further provides anentrance to said pocket which entrance facEs said strain relief meanswhen said upper and lower portions are secured together.
 4. A protectorfor the stripped terminal ends of insulated electrical conductors asdescribed in claim 1, including: a metal connector disposed in saidpocket for receiving said stripped terminal ends; and said locking meansin said pocket engages said metal connector for releasably locking saidmetal connector in said pocket.
 5. A terminal protector as described inclaim 4, wherein: said locking means in said pocket includes a latchfinger formed of a resilient material to releasably engage said metalconnector; and said latch finger engages the end of said metal connectorlocated adjacent said strain relief means.
 6. A protector for thestripped terminal ends of insulated electrical conductors as describedin claim 1, including: a metal connector disposed in said pocket forenclosing said terminal and the external diameter of said metalconnector is smaller than the internal diameter of said pocket to causean interference fit when said metal connector is placed inside of saidpocket.
 7. A protector for the stripped terminal ends of insulatedelectrical conductors as described in claim 1, wherein: said elongatedflexible body being generally in the shape of a flat strip; said pocketbeing supported on an intermediate portion of said body strip; said bodystrip being foldable about said pocket; and said upper and lower strainrelief portions, located on said body strip end portions, beingsecurable together for locking said conductors in said undulatingpassageway and retaining said body strip intermediate portion foldedabout said pocket.
 8. A protector for the stripped terminal ends ofinsulated electrical conductors as described in claim 1, wherein saidmeans providing a pocket being removably supported in an opening in saidbody; said means providing a pocket having an enlarged portion at oneend thereof to prevent said pocket providing means from pulling throughone side of said body opening: and said strain relief means, when lockedabout said conductors, being arranged with respect to said pocketproviding means to abut said enlarged portion to prevent removal of saidmeans providing a pocket from the second side of body opening.
 9. Aprotector for the stripped ends forming the terminal of electricalconductors, comprising: a. a body of flexible insulating material; b. apocket supported on said body for enclosing the stripped ends ofconductors forming a terminal; c. locking means in said pocket forlocking said terminal and said conductors in said pocket; d. cord strainrelief means on said body beyond one end of said pocket for locking saidconductors to said body independently of said locking means for saidterminal and conductors; and e. said body formed of molded plasticmaterial with said pocket forming an integral part thereof, and threadmeans molded in the interior of said pocket for receiving said strippedends of said conductors, rotation of said stripped ends along saidmolded thread means splicing said ends together and securing the latterin said pocket.